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CONSTRUCTION GUIDELINES

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INTRODUCTION

PAL Pre-insulated Ducting System is an innovative technology for


manufacturing of revolutionary foam based pre-insulated ductwork
for Heating Ventilation and Air Conditioning systems as alternative to
sheet metal ductwork.
PAL Pre-insulated Ducting System provides a wide range of accessories
and consumption materials which allow the assembly of any shape
and dimensions of ducts, using few and simple tools. All production
phases are carried out at quality conditions, from the choices of raw
materials, to the production process and final product evaluation. To
guarantee the perfect product use, training courses are conducted
to ensure proper procedures are done accordingly to provide high
quality final product to meet every needs in HVAC installations.

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METHOD STATEMENT
FABRICATION OF DUCTWORK
All personnel responsible for the fabrication and construction
of ductwork systems shall, prior to being engaged in the
work, have successfully completed the specialized PAL Preinsulated Ducting System training course and shall be familiar
with all aspects of the fabrication techniques necessary for
the manufacture of the complete system. All trainees who
successfully complete the training course are awarded a PAL
certificate of competency. PAL Pre-insulated Ducting System
offers a complete product line providing all tools, accessories
and components necessary to fabricate ductwork. Each item has
been rigorously tested in the field to the highest of standards
in a variety of applications. Under no circumstance are any
substitute components to be used in place of approved PAL
products.
It is therefore recommended that the fabricator adopt

PROCEDURES

the convention of internal measurements during plotting.


Accordingly, all tracing and plotting will take place on the

The construction of a duct is accomplished by following a

internal side of the duct.

standardized procedure. The process is the same regardless of


the shape of the duct element:

2. Cutting

Tracing

The operation involves cutting 45o miter cuts along each edge

Cutting

of the duct. The V-grooves made by the 45o Double Blade Jack

Gluing

Planes enable the panel to be folded into shape. The V-grooves

Folding

is also ideal for the subsequent gluing operation as it provides

Taping

maximum surface area. The material that is discarded as a result

Sealing

of this operation must have been accounted for during the

Flanging and reinforcement

previous tracing. There are also several other special purpose


Jack Plane available including the 22.5o and the Adjustable.

Although each of the above operations is described in general


below, this speciation is by no means intended to serve as an
instruction manual to replace the training course. Note that
when properly constructed, the finished duct segment will have
no exposed foam neither internally nor externally.
1.Tracing
The tracing of the duct outline onto the panel is the first step of
the process. This is accomplished by utilizing the teflon pencils
supplied in each tool box which scribe a line as opposed to
marking an ink line. Note that all measurements specified on
drawings of duct systems refer to a ducts internal dimension.
This corresponds to the cross-sectional area of the air passage
necessary to satisfy design requirements.

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3. Gluing

5. Taping

The glue is a contact adhesive in containers that must be well

Aluminum self adhesive tape is provided. The tape has been

shaken prior to use in order to assure uniform consistency.

double cured for increased pliability, and contains two and one-

The glue can either be applied with a pneumatic glue spreader,

half times as much glue as standard tapes; also, it is a special

or sprayed on with a pneumatic glue gun. Glue is applied evenly

glue with high technical characteristics to ensure maximum

to mitered surfaces covering all exposed phenolic material.

adhesion. The taping of the duct serves four purposes:

Note that the V-grooves should first be swept clean of any

1. It re-establishes the vapor barrier within the mitered cuts.

remaining phenolic dust. Depending on the temperature and

2. External seams are taped to improve the ducts aesthetic

relative humidity, the adhesive requires approximately 10 to


20 minutes to cure during which time the solvents evaporate.

appearance.
3. Tape is used to repair and cover any damage to the panel,
both externally and internally, and
4. It seals and isolates the phenolic material from the
surroundings.

This operation should be performed in a well ventilated area


and the precautions recommended on the COSH (Certificate
of Safety and Handling) sheer should be observed. The curing

Prior to applying the tape, ensure that all surfaces are dry and

period is complete when the glue is dry to the touch.

free of dirt, oil, silicon, and grease. If the surface cannot be


thoroughly cleaned, then a simple solution is to apply a light

4. Folding

coat of glue on the surface where the tape is to be placed


(note that the glue must be allowed to cure first, as discussed

Following the curing phase, the sides are folded at right angles to

within Section 3 above). The tape should ideally be applied

each other (90o) and the duct shape is formed. Note that when

in temperatures above 10oC (50oF) in order to assure a good

two open sides of a duct are joined together, the aluminum foil

bond. The tape should not be applied to the ducts surface

edge of the miter cut on the internal surface should be used

when the temperature is below 0oC (32oF) due to the potential

for aligning purposes. When a duct is comprised of several

entrapment of ice crystals.

individual pieces, the joining process should always be initiated


from the same end so that the subsequent trimming operation

Tape is only applied to seams where the external surface of

of any excess length is only required at the opposite end. The

the aluminum foil has been cut. On sides where the panel has

black hard spatulas should then be used to firmly crease along

been simply folded, as opposed to joined, no tape is required.

the edges of the duct to ensure maximum adhesion in the

The tape-marker is used to scribe a line on the panel which

V-grooves.

serves as reference during application of the tape. The soft


spatula is brushed firmly along the surface of the tape during
application to ensure maximum adhesion and to expel any air
bubbles trapped underneath. When taping reducers or elbows,
the tape must always be applied to the curved or creased side
(not the straight side), and the supplemental directions within
the respective sections should be observed.

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6. Sealing
Following assembly of the duct segment, all internal joints
must be sealed with silicon. In addition to imparting greater
strength and rigidity, the primary function of the silicon is to
hermetically seal the internal surface of the duct and prevent
any phenolic particles from entering the air stream. It is
recommended that after the silicon bead has been applied, a
radiused tool (or alternatively a wet finger) is gently run along
the entire length of the bead to duct wall. Proper application is
imperative in order to ensure clean air and minimal leakage.
7. Aluminum Profile and Reinforcement
There are a variety of aluminum profiles available to suit various installation requirements. Depending on both the system pressure and
the ducts dimensions, the installation of a reinforcing bar may be necessary.

CUTTING TOOLS
Double Blade Cutter 45o

Single Blade Cutter 45o Left

Single Blade Cutter 90o

Single Blade Cutter 45o Right

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CUTTING TOOLS
Single Blade Cutter

STRAIGHT DUCT METHOD: Method 1

Cutting along the panel length


The sum of 4 sides less than 1040mm (2H + 2W)

Sequence of Assembly

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STRAIGHT DUCT METHOD: Method 2A

Cutting along the panel length


The sum of 3 sides less than 1080mm (2H + W or 2W + H)

Sequence of Assembly

STRAIGHT DUCT METHOD: Method 2B

Cutting along the panel length


The sum of 2 sides less than 1120mm (W + H)
Sequence of Assembly

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STRAIGHT DUCT METHOD: Method 2C

Cutting along the panel length


Each side to be less than 1160mm

NOTE
Extra Silicon (bigger tip cut)
When assembling the four sides, the sides should be checked (with T Square Ruler) and held in position

STRAIGHT DUCT METHOD: Method 3

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END CAPS

TRANSITIONS

Concentric Transition

Eccentric Transition

max. 20 (D = 3 x A)

max. 20o (D = 3 x A)

suggested 15 (D = 4 x A)

suggested 15o (D = 4 x A)

OFFSETS

Offset Angled

Offset _ Radiused

max. 30 (D = 2 x A)
o

ECCENTRIC REDUCER
Dimension in mm
D suggested = 4 x (450-300)
= 600:D minimum = (450-300) = 150

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CONCENTRIC REDUCER

Dimension in mm
D suggested = 2 x (450-300) = 300:D minimum
= 1.5 (450-300) = 225

ELBOW

LEGEND:
N = Neck
ER = External Radius
IR = Internal Radius
TVR = Turning Vane Radius
Dimension in mm
Numbers in the hoop show suggested tracing procedure

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DYNAMIC BRANCH

Dimension in mm
Numbers in the hoop show suggested tracing procedure
D suggested = 4 x (540 400) = 560; D minimum = 3 x (540-400) = 420

ASSEMBLY PROCEDURE

Place 1 on the table


Join section 2 and Section 3 to 1
Install Section 4
Install Section 5
Install Section 6

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TEE BRANCH (External Side Flushed)

Dimension in mm
Numbers in the hoop show suggested tracing procedure

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TEE BRANCH (Internal Side Flushed)

Dimension in mm
Numbers in the hoop show suggested tracing procedure

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ASSEMBLY PROCEDURE

Place 1 on the table


Join section 2 and 3 only the Neck Section
Add pieces (scraps) 5 and 6 with just Tape and on Glue
Install bigger Circumference Section with cover 7
Install Section 8
Remove section 5 and glue section 3
Remove section 6 and glue section 2

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CONNECTION TO ACCESSORIES

Flanged Damper

Spiggoted Damper

CONNECTION TO SHEET METAL

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TAKE OFF

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TAKE OFF (above 1000 x 1000mm)

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TAKE OFF (up to 1000 x 1000mm)

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PROFILES FOR ACCESS DOORS

GRILL INSTALLATION (with Turboscrews)


The

Turboscrew

the

installation

greatly

simplifies

doors,

etc.

The turboscrew is easily screwed into the


panel utilizing the simple tool provided and
has a large thread which ensures a secure
fit. The standard attaching screws for the
grill are then screwed into theTurboscrew.
The only constraint is the attaching
screws are 4 5mm in diameter and not
longer than the thickness of the grill plus
22mm.

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OPTION 1 Duct Joining System

20mm
Ducting
Joint
System

30mm
Ducting
Joint
System

OPTION 2 For Internal Duct (20mm thick)


Less than 500 x 500mm Section
Male Female Joining System

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OPTION 2 For Internal Duct (20mm thick)


Less than 500 x 500mm Section

STEP 1
Application of Aluminum Tape on
both ends of the duct segments

STEP 2
Silicon is placed on one side of one duct, then
the two duct segments are joined together

STEP 3
Tiger Connectors are placed on all
four sides of the duct.
For small ducts up to 300mm, use ONE Tiger
Connector on each side of the duct.
For ducts with one side 350 to 500mm,
use TWO Tiger Connectors on each side.

STEP 4
Aluminum Tape covers the connection of the
two duct segments.

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GRILL INSTALLATION with Aluminum Profiles

P1 FITTINGS INSTALLATION
for Round Diffusers & Flexible Ducts

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DUCT REINFORCEMENT

Table for the Calculation of Stiffening

D = Recommended Step Interval (see schedule of Duct Reinforcement)


W = Width of Duct

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HANGER SYSTEM

DUCTWORK SUPPORT DETAIL

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P.O. Box 113826 Dubai, United Arab Emirates


T +971 4 258 2640 F +971 4 258 2641 Email palme@emirates.net.ae
Visit www.pal-me.net

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